Audi V6 TDi 2.7 & 3.0 Inlet Manifold, Swirl Flap Repair Kit.

**Jim Boyle** · 15-01-2013,09:51 PM

I had just applied my own fix to one side of a V6 when I saw the post on repair kits. Went back to Audi dealer who had quoted £1700 to fix problem and ordered two repair kits for £17.38, collected today. Logically only half of the wear will be on the replaceable parts, the other half on the manifold. In case anybody needs it, here is my fix: The problem is caused by the actuator reporting a larger (and possibly variable) angle of movement than when it was initially set up. I made a plate to fit on the front of the actuator with adjustable stops, which limit movement. I thought it may be difficult to set, but was right first time. No need to mount the actuator to test, just plug in. It can still drive the flaps, but I just wired the rod in the fully open position to one of the mountings. The light stayed out.
FlapMotorMod.jpg

**SRT88** · 15-01-2013,10:50 PM

It is not quite clear to me what you have done...Could you please post several photos?
Thanks

**gupsterg** · 15-01-2013,10:54 PM

Thanks for your solution, always great to see DIY fixes

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You can buy new swirl flap motors separately...

VDO P/N enter car data in here Link:- online catalogue ...

Audi P/N 059 129 086 M (same part used both sides)... Audi Approx price £200 ...

Just seen a listing on ebay genuine Audi part £140 ...

IIRC there is/maybe a calibration which must be done when new ones are fitted...

**tonyandkaty** · 16-01-2013,10:20 AM

Do Audi stock the swirl flap repair kit ??, as when I contacted my local dealer they said there is no repair kit and you can only buy the whole unit. So glad I found that repair kit for £21 and the light is still off even after a drive to scotland and back

**gupsterg** · 16-01-2013,10:41 AM

Yep the P/N I've posted is what I gave to Audi main dealer parts dept and collected... will add copy of invoice here later this evening if that helps anyone get them

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**tonyandkaty** · 16-01-2013,10:49 AM

Maybe it was just the dealer trying to get as much money as possible and did not want anyone to know about the parts they probably fit when people come in for new swirl motors lol.

**gupsterg** · 05-02-2013,01:43 PM

Here is my invoice peeps

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Sorry for delayed updated

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**as400** · 05-02-2013,10:32 PM

So in terms of preventative medicine, who should be seriously considering buying these kits and getting them fitted?...should I be worried?...car has just hit 100K and is running perfect, are there any symptoms prior to swirl flap failure?....went in for a major service with Audi a couple of months ago and nothing was mentioned?

**rafletcher** · 06-02-2013,03:29 PM

No symptoms at all - and none after the "failure", just the emissions light on and (I beleive) the flaps not working at low revs as they would usually. I certainly couldn't feel a difference. Mine went at 62k. Audi dealer would only see it if there WAS the error and the light was up - no light, no error to scan for.

I'd also take issue with Jim B that "half the wear will be on the manifold". Dissimilar materials will wear at different rates, so there's no guarantee it's a 50/50 split, and may well mainly be on the levers "socket" part of the joint.